Molecular Separator

ABSTRACT

The present invention discloses a method and apparatus for separating particles and dissolved matter from an untreated fluid stream. Specifically, the present invention includes a first pressure source which transports untreated fluid or contaminated aqueous fluid into a separator annulus with a filter element disposed therein. The untreated fluid is placed under appropriate pressure sufficient to produce turbulent flow, increased particle kinetics and/or cavitation allowing the desired fluid to penetrate and pass into and through the filter media. The treated fluid is then transported to a collection tank. The contaminant matter retained by the filter media may be removed by the nearly instantaneous reverse pressurization of the separator annulus by a second pressure source thereby removing the contaminant particles away from contact with the filter media, and which may then be transported to a waste collection tank or a separator for further treatment.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation-in-part and claims the benefit of andpriority to co-pending U.S. patent application Ser. No. 11/042,235,attorney docket no. CJOHN.00002CIP which was filed on Jan. 25, 2005,which claims the benefit of and priority to U.S. Pat. No. 7,291,267,attorney docket no. CJOHN.00002 filed on Apr. 8, 2004, which claims thebenefit of and priority to U.S. Provisional Application No. 60/540,492,filed Jan. 30, 2004, the disclosures of which are incorporated herein byreference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not applicable.

INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

Not applicable.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to an improved apparatus and system forimproving the quality of fluids untreated from petroleum and gas welldrilling and recovery operations, mining operations, and during otherindustrial activities, and specifically to a method that does not simplyinvolve the use of traditional filtration or separation methods. Thepresent system separates contaminants from a variety of fluids utilizinga pressure separation apparatus which can also create and facilitatehydrodynamic cavitation conditions within the fluid. This results in theimproved separation and removal of particulates and dissolvedconstituents from the fluid.

2. Description of Related Art

The safe and effective removal of contaminants from fluids is aconsistent problem faced by many industries. The impurities accumulatedby fluids during the hydrologic cycle, industrial processes andmanufacturing activities may appear in both suspended and dissolvedforms. Suspended solids may be generally be classified as particleslarger than molecular size (i.e. particle sizes greater than 10⁻³ mm),which are supported by buoyant and viscous forces existing within thefluid. Dissolved materials (i.e. particle sizes less than 10⁻³ mm)consist of molecules and ions, which are held by the molecular structureof fluid.

The presence of suspended and/or dissolved solids in waste fluid andother fluids is undesirable for several reasons. The presence of visiblesuspended solids may be aesthetically displeasing. Likewise, thepresence of suspended and/or dissolved solids allows for the adsorptionof other chemicals or biological matter into the fluid. Due to thestandards promulgated by government agencies, excessive contaminantsmust be removed from potable fluid, waste fluid and other types ofcontaminated fluid streams before the effluent may be discharged to theenvironment or recycled for reuse. If establisheddischarge-contamination levels are exceeded, governmental authoritiesand agencies may impose surcharges and penalties on the entityresponsible for the discharge of fluids which do not meet or exceed theappropriate standard of quality.

For example, both terrestrial and offshore oil and gas fields producelarge quantities of contaminated fluid that can have significantenvironmental effects if they are not handled, remediated and dischargedproperly. In a typical petroleum formation, formation fluid liesadjacent the formation layer containing the desired hydrocarbons (e.g.oil and natural gas). As a result, when these hydrocarbons are removedfrom the formation via the wellbore, formation fluid is brought to thesurface along with the hydrocarbons. Drilling fluids are utilized toassist in oil and gas well drilling operations. If required and in orderto achieve maximum recovery, recovery fluids will be injected into theformation to provide additional motive force to recover the hydrocarbonsfrom the formation. As a result, increasing volumes of both formationfluid and injected fluid are produced and remain untreated in therecovery of oil and gas from the formation. The treatment of untreatedfluid is a major component of the cost of producing oil and gas.

Untreated fluid characteristics and physical properties varyconsiderably depending upon the geographic location of the field, thegeological formation with which the untreated fluid has been in contactfor thousands for years, and the type of hydrocarbon product beingrecovered. The contaminants of untreated fluid may include salt contentexpressed as salinity, conductivity, or total dissolved solids (“TDS”).Other contaminants may include slurries having dispersed oil droplets,dissolved organic compounds including dissolved oil, drilling fluids,polymers, well treatment and workover chemicals, and other organic andinorganic compounds that can lead to toxicity. Some of these arenaturally occurring in the untreated fluid while others are related tochemicals that have been added for drilling and well-control purposes.Further, contaminants can also include dissolved gases includinghydrogen sulfide and carbon dioxide, bacteria and other livingorganisms, and dispersed solid particles. Untreated fluids alsotypically exhibit low concentrations of dissolved oxygen andnon-volatile dissolved organic materials. Because of the contaminants inuntreated fluid, it requires no large amount of thought to surmise thatthe direct release or reinjection of untreated fluid into the ocean,upon land, or into the subsurface formation would have damaging effectson the environment and pose health risks to animals and humans in boththe short and long term.

One prior art solution for treating untreated fluid involves pumping thefluid through disposable filters to filter and remove the suspendedsolids. There are several problems with this prior art solution. First,once the disposable filters have been used they are typically consideredhazardous waste and they must be sent to special disposal facilities fordisposal after use further depleting the increasingly diminishinglandfill space available. Second, the disposable filters are themselvesrelatively costly and therefore do not provide an economical treatmentsolution. Third, the constant changing of used disposable filters withclean or new disposable filters is labor intensive. Fourth, thedisposable filters have a relatively short lifespan as they (1) areconstructed of paper-based material which is easily degraded bycontaminants, (2) are unable to continually support the sheer mass ofthe contaminants that are loaded onto the filters during filtrationoperations, and (3) cannot withstand typical backwash cleaningpressures. Consequently, a need exists for a way to minimize oreliminate the need for disposable filters in the removal of suspendedsolids from waste streams such as untreated fluid.

Another problem encountered in removing contaminants from fluids is theexpense and difficulty in designing a system that can removecontaminants that vary widely in chemical and physical make-up. Asalluded to above, the chemical make-up of contaminants ranges widelyfrom dissolved oil and brine to bacteria in untreated fluids. Similarlythe physical make-up of the contaminants varies in particle size fromthe ionic range (brine) to the micro and macro particle range (oildroplets, sand particles). Such a wide range of contaminants presentsseveral challenges in treating untreated fluids. For example, slurriesand biological contaminants can plug filtration equipment, andseparation of metals from contaminated fluid typically requiresexpensive chemical precipitation processes. These are just a sampling ofthe difficulties encountered in the treatment of industrial waste fluidwhich illustrate the complexity and expense of treatment facilities thatmust be constructed to treat such waste fluid in lieu of disposablefilters. Because such treatment facilities are complex, they aretypically not mobile, therefore requiring industrial waste fluid bestored on-site and then shipped to a treatment facility. Consequently, aneed exists for an improved method and apparatus for treatingcontaminated fluid. In one aspect, the apparatus and method should bemobile and able to be economically installed near the location where theuntreated contaminated fluid originates. In another aspect, theapparatus and method should provide sufficient treatment to meetregulatory standards required to permit discharge of fluid directly intothe environment and/or for reuse in industrial settings. Further, themethod and apparatus should be able to provide for the treated fluidneeds of the facility where the apparatus is located. As such, a needexists in the art for a portable, highly efficient filtration apparatusand method which can separate suspended and dissolved solids and othercontaminants in a variety of environments. Further, a need exists for animproved apparatus and method of removing particles from fluids ineither a liquid or gaseous state. Further, a need exists for anapparatus and method which can consistently remove particles of adesired size so as to efficiently and consistently reduce the chance ofthe imposition of a surcharge for violating quality control standardsand the release of untreated effluents.

SUMMARY OF THE INVENTION

The present invention discloses a method and apparatus for separatingparticles, dissolved matter and chemical sub-fractions from a fluidstream. In one embodiment, the present invention also discloses a novelseparator design which creates or enhances particle kinetics andcavitation physics to increase filtration efficiency and provides forthe separation of chemical sub-fractions from fluid streams below onemicron in size. In one aspect, the untreated fluid is placed underpressure sufficient to enhance standard filtration, create or enhanceparticle kinetic reactions, and/or to create or enhance hydrodynamiccavitation during the separation process wherein suspended and dissolvedcontaminants are separated from the fluid stream within the separator byone or more of said processes during the separation phase. The treatedfluid may then be transported to a product collection tank, discharged,or sent to additional treatment or polish mechanisms. The particulatematter retained by the reusable filter media is removed by theinstantaneous reverse pressurization of the separator thereby forcingtreated waste away from the reusable filter media and into a rejecttank. The waste from the reject tank can then further be treated,optionally, by further dewatering and minimization processes. Anyresulting sludge can be further processed as necessary and the driedwaste can then be transported to a waste collection center forappropriate disposal or landfilling. The treated effluent may be safelyused in a variety of ways including, but not limited to, beingdischarged to the environment for beneficial reuse (e.g. potable fluiduse or agricultural use), utilized for secondary and tertiary oil/gasrecovery operations (e.g. frac fluid and steam flooding) or injectedinto disposal wells.

Other aspects, embodiments and features of the invention will becomeapparent from the following detailed description of the invention whenconsidered in conjunction with the accompanying drawings. Theaccompanying figures are schematic and are not intended to be drawn toscale. In the figures, each identical or substantially similar componentthat is illustrated in various figures is represented by a singlenumeral or notation. For purposes of clarity, not every component islabeled in every figure. Nor is every component of each embodiment ofthe invention shown where illustration is not necessary to allow thoseof ordinary skill in the art to understand the invention. All patentapplications and patents incorporated herein by reference areincorporated by reference in their entirety. In case of conflict, thepresent specification, including definitions, will control.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are setforth in the appended claims. The invention itself, however, as well asa preferred mode of use, further objectives and advantages thereof, willbest be understood by reference to the following detailed description ofan illustrative embodiment when read in conjunction with theaccompanying drawings, wherein:

FIG. 1 illustrates a process flow diagram for a fluid treatment systemin accordance with one embodiment of the present invention;

FIG. 2A is a schematic diagram illustrating the interaction of thefunctional components of the system in which influent fluid is treatedwith a single flux cartridge unit in accordance with one embodiment ofthe present invention;

FIG. 2B is a schematic diagram illustrating the interaction of thefunctional components of the system in which influent fluid is treatedwith a single flux cartridge unit in accordance with an alternativeembodiment of the present invention;

FIG. 3 is a schematic diagram illustrating a cross section of a singleflux cartridge unit according to the present invention;

FIG. 4 provides a more detailed cross-sectional view of the fluxcartridge membrane of a flux cartridge;

FIG. 5A is a cross-section view of the filter membrane of the fluxcartridge inside the annulus of a separator;

FIGS. 5B-5C provide a more detailed prophetic view of the tortuous paththe influent fluid travels as it is forced through the separation media;

FIG. 5D is a schematic diagram illustrating a cross section of a singleflux cartridge unit comprising an electrochemical cell according to oneembodiment of the present invention;

FIG. 5E provides a more detailed cross-sectional view of the fluxcartridge subjected to a magnetic field in accordance with oneembodiment of the present invention;

FIGS. 6A-6C show the use of multiple stages or passes of influent fluidthrough the apparatus (or series of apparati) in series, parallel and incombination, respectively;

FIG. 6D shows the use of heat to improve the removal of contaminantsfrom influent fluid as it passes through the filtration stages; and,

FIG. 7 is a schematic of a multi-stage filtration system wherein thereis a first set of apparati in series and then a second set of apparatiin parallel according to one embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention is directed towards an improved fluid treatmentsystem for removing contaminants from a variety of fluids, including butnot limited to, waters, synthetic fluids, oil and petroleum basedfluids, gases and other fluids occurring naturally and which are alsomanmade. In one embodiment, the use of hydrodynamic cavitation forcesand physics in conjunction with traditional separation media to treatcontaminated fluid is both novel and a significant improvement overexisting filtration systems. “Untreated fluid” or “influent fluid” isused throughout the detailed description and refers to any fluidcontaining one or more contaminants. As used herein “untreated fluid” isused interchangeably with “influent fluid.” As used herein,“contaminant” refers to any physical, chemical, biological, orradiological substance or matter which is to be entirely orsubstantially removed from the fluid in which the contaminant issuspended, dissolved or otherwise entrained.

FIG. 1 illustrates a simplified process flow diagram for a fluidtreatment system in accordance with one embodiment of the presentinvention. As shown in FIG. 1, untreated fluid is stored in a tank 10.Depending on the solids content of the untreated fluid, the untreatedfluid can be routed via a pump 20 or other suitable means to acentrifuge 30 or dissolved air flotation system (DAF) to remove asubstantial portion of suspended particles, such as sand, dirt, gravel,and other similar material. These constituents can be routed to a rejecttank 60 where they can optionally be dewatered, pressed or stored forfurther processing or disposal 70. In one embodiment, the untreatedfluid is routed directly to the molecular separator 40 without beingrouted to a centrifuge or other similar device.

In one embodiment, additives 12 can be added to the untreated fluid 10near the pump inlet as shown in FIG. 1 and/or directly to the start tank10. In one embodiment, the additives 10 can be added to help control orremove biological organisms or activity in the untreated fluid streamthat can promote fouling of the flux cartridge as discussed in moredetail below. Additives include, but are not limited to, sodiumhypochlorite, chlorine (Cl₂), chlorine dioxide (ClO₂), bromine (Br₂),iodine (I), ozone (O₃), bleach, ammonia, metal ions (e.g. Ag⁺ and Cu²⁺),phenols, alcohols and other chemical disinfectant additives as known inthe art. The untreated fluid from the waste tank can be treated in themolecular separator apparatus 40 to remove contaminants from theuntreated fluid with the use of reusable filter media. The molecularseparator apparatus 40 also provides the ability to concentratecontaminants and routes the contaminants to the reject tank 60 androutes treated fluid or product to a product storage tank 50. In oneembodiment, the treated fluid from the molecular separator apparatus 40can be further polished by routing the treated fluid through adisposable nano-filter (not shown) and/or by routing the treated fluidthrough a reverse osmosis system 52. The operation of one embodiment ofthe molecular separator apparatus 40 is discussed in more detail below.

FIG. 2A is a schematic diagram illustrating the interaction of thefunctional components of the system in which untreated fluid is treatedwith a separator containing a single flux cartridge unit in accordancewith one embodiment of the present invention. Untreated fluid can berouted from a centrifuge 30 as shown in FIG. 1 or it can come directlyfrom a storage tank 401, as depicted in FIG. 2A. The untreated fluid maycontain sulfur compounds, heavy metals, carbonates, brines, salts,drilling fluids, polymers, industrial solvents, or any similar fluid orsolid, in either dissolved or suspended form or both, which are to beseparated from the fluid.

FIG. 3 is a schematic diagram illustrating a cross section of a singleflux cartridge seated within the annulus of a separator according to thepresent invention. A plurality of these flux cartridges seated withincorresponding annuli may be assembled in parallel or series and comprisethe separator. With reference to FIG. 3, a flux cartridge unit orseparator 100 comprises an outer casing 110 forming an annulus region orfluid ring 160 around a single flux cartridge 120. The outer surface ofthe flux cartridge 120 is shown. The inside region 130 of the fluxcartridge 120 is hollow. A sealing ring 140 on the flux cartridge 120ensures that no fluid passes between the annulus 160 and the insideregion 130 of the flux cartridge 120 when the flux cartridge 120 issealed in the separator 100.

FIG. 4 provides a more detailed cross-sectional view of the fluxcartridge membrane of a flux cartridge 120 and the filtration ofuntreated fluid as disclosed herein. Untreated fluid is directed intothe annulus region 160 and through the flux cartridge 120 underpressure. Influent fluid enters through an entry port or region 260under pressure. Due to the pressure differential between the annulusregion 160 and the interior region 130 of flux cartridge 120, asubstantial portion of contaminants are retained on the surface andwithin the interior fissures of the flux cartridge 120, while thedesired fluid effluent or product is collected in the interior region130 of the flux cartridge 120 and routed out of the flux cartridge 120via fluid outlet 270. To further enhance the separation process, thepressures of the system can be manipulated by the user so that thepressure drop experienced by the fluid moving from the smaller diameterinlet 260 into the larger volume of the annulus 160 creates theformation of cavitation bubbles resulting in additional filtration andchemical effects as further discussed herein.

Referring back to FIG. 2A, in one embodiment, the filtration processbegins by drawing the untreated fluid from the storage tank 401 by meansof a first pneumatic pump 410. The pneumatic pump 410 alternately drawsthe untreated fluid through two poppet valves 411, 412 via the upwardand downward motion of a plunger 413, and alternately pumps the influentfluid through two outlet lines 414, 415. Although only one separator 100is depicted, each outlet line 414 and 415 can route fluid to a header influid communication with other separators 100. Referring back to FIG.2A, pressurized untreated fluid is delivered to the separator via lines414 and 415. The poppet valves in the valve assembly, which is in fluidcommunication with the separator via transition plates, control themovement of untreated fluid into the separator. As the plunger 413 rises(as shown in the present example), fluid is drawn through a poppet valve412. Simultaneously fluid is pumped out through the upper outlet line414. When the plunger 413 reverses direction and pushes downward, thelower poppet valve 412 closes and the untreated fluid is drawn throughthe upper poppet valve 411 and pumped out through the lower outlet line415. The untreated fluid moves through the outlet lines 414, 415 to aseparator 100 and specifically into the annulus or fluid ring 160. Forthe purposes of FIG. 2A, a single separator 100 with flux cartridge 120inserted therein is shown for ease of illustration. In one embodiment,the separator contains eight annuli with eight corresponding fluxcartridges seated therein and may be referred to as a Q-Pod. Transitionplates attached to the opposite ends of each separator provide for thedistribution of incoming untreated fluid, treated fluid, and backwashfluid into and out of the separator as described herein. Alternativeconfigurations with additional or fewer annuli and flux cartridges arepossible and contemplated herein.

FIG. 2 is a schematic diagram illustrating the interaction of thefunctional components of the system in which untreated fluid is treatedwith a single flux cartridge unit 100 in accordance with an alternativeembodiment of the present invention. Referring to FIG. 2B, a centrifugalpump 420 or other suitable pump is used to pump fluid from a storagetank 401 through an outlet line 421 and into a header 422 in fluidcommunication with the separator 100. Although only one flux cartridgeunit 100 is depicted, the outlet line 421 can route fluid to a header422 in fluid communication with other flux cartridge units 100.

With reference to FIGS. 2A and 2B, seated within the separator 100 is aflux cartridge 120. A flux cartridge 120 comprises a membrane thatassists in the separation of contaminants from the untreated fluid. Aspace (referred to herein as a fluid ring 160) exists between the insidesurface of the separator 100 and the outer surface of the flux cartridge120. As untreated fluid is delivered to the separator with the firstpump outlet line 414, it passes through poppet valve 424 and into thefluid ring 160. When the untreated fluid is delivered with the second orlower pump outlet line 415, a corresponding poppet valve 424 closes andthe fluid passes through a second poppet valve 423 and into the fluidring 160.

Referring to FIGS. 2A, 2B, and 4, once in the fluid ring 160, theuntreated fluid moves in a turbulent manner whereby contaminants areremoved via pressure filtration, particle kinetics and/or hydrodynamiccavitation as discussed in greater detail herein. Fluid passes into andthrough the flux cartridge membrane and into the interior chamber 130 ofthe flux cartridge 120. Contaminant particles and larger molecules 210are left behind as residue in the fluid ring 160, and on the exteriorand within the fissures of the flux cartridge 120. The pressure suppliedby the first pump 410 transports the treated product out of the centerof the flux cartridge 120 through a flux cartridge exit valve 427 andinto a second pump, called a pneumatic ejector pump 430. Alternatively,the treated fluid product may leave the flux cartridge 120 through anejector bypass valve 428 and travel directly to a product collectiontank 402. This ejector bypass is typically used when a single ejectorpump 430 services multiple separator filter pods in alternativeembodiments of the present invention.

During the filtration cycle described above, the ejector pump plunger431 is drawn up (as shown in FIGS. 2A and 2B) into a charged “ready”state. Next, check valves 432, 433 that are built into the plunger'sdisc are opened. In this position, the check valves 432, 433 allow thetreated product coining from the flux cartridge 120 to pass by theplunger 431 and out of the ejector pump 430 and into the productcollection tank 402. The filtration cycle continues for eachannulus/flux cartridge within the separator pod for a pre-determinedtime period (e.g. 20-25 seconds) or until separation efficiency declinesbelow a pre-determined level. At the end of this separation cycleperiod, each annulus/flux cartridge within the separator is backwashedand cleaned with a reverse flush (ejection cycle). The annuli/fluxcartridges can be backwashed all at once, or programmed to backwashindividually at the desired interval or designated pressuredifferential, thereby allowing the system to maintain continualfiltration in select annuli/flux cartridges while backwashing otherindividual annuli/flux cartridges at the same time. Alternatively, asensor assembly may be employed to measure the pressure drop across theflux cartridge or other appropriate location. When the pressuredifferential becomes excessive, or reaches a certain value, the sensorassembly sends a corresponding signal to the central controller whichinitiates reverse flush operations (ejection cycle). Such sensorassemblies are known in the art and further description thereof isconsidered unnecessary.

Referring to FIG. 2A, the reverse flush operation or ejection cyclebegins by stopping the first pump 410 and shutting the poppet valves423, 424 at the top of the separator 100 of the separator filter pod. Inanother embodiment wherein multiple separators (not shown) are servicedby first pump 410, first pump 410 continues to operate while eachindividual separator 100 or alternatively, each individual andannulus/flux cartridge is taken offline for the reverse flush cycle. Inthe embodiment using the centrifugal pump 420 depicted in FIG. 2B, thepump 420 is not shut off as it is still serving other separators (notshown) when one or more of the separators is in the backwash cycle.Next, the pneumatic ejector 430 is activated and its plunger 431 isdriven downward. This motion closes the plunger's check valves 432, 433and stops the flow of treated fluid past the plunger 431, allowing theplunger to exert pressure on the fluid inside the ejector. Clean rinsefluid is transported back through the flux cartridge exit valve 427,through the flux cartridge 120 and into the fluid ring 160. The timeperiod for this reverse ejection flush or ejection cycle isapproximately 0.35 seconds and is carried out under higher pressure thanthe normal filtration cycle driven by pump 410. For example, thepressure exerted on the untreated fluid by the first pump 410 may be upto 150 psi (1.03 MPa) depending on the viscosity and other physicalcharacteristics of the fluid involved. In contrast, the pressure exertedby the ejector 430 during the reverse flush may be up to 300 psi (2.06MPa). This quick, high-pressure reverse burst removes contaminantparticles and residue remaining within the fissures and outside surfaceof the flux cartridge 120 and re-homogenizes the particles and residuein the fluid ring 160. By utilizing treated fluid to clean theseparator(s), there is no need for an external backwash fluid source.

In the next phase of a typical cycle, a poppet valve 426 on the bottomof the separator 100 is then opened to allow the pressurized contaminantparticles and residue solution to flush out of the fluid ring 160 andinto a concentrator annulus 442 or directly to a reject collection tank403. The concentrator annulus 442, as its name suggests, concentratesthe material backwashed and flushed from the separator 100 by removing asignificant portion of the flush fluid used during the ejection cycle.Unlike the separator filter pod, which may contain up to eight annuli inthe preferred embodiment, the concentrator 440 contains only one annuluswith a flux cartridge 441 seated therein in a preferred embodiment. Theflushed contaminant waste enters the concentrator annulus 442 through anopen poppet valve 443 and into the interior chamber of theconcentrator's flux cartridge 441. The desired effluent fluid passesthrough the membrane of the flux cartridge 441 and into the fluid ring442, leaving the concentrated contaminant waste residue in the interiorchamber of the flux cartridge 441. A fluid return poppet valve 447 inconnection with the bottom or one end of the separator annulus 442allows the treated fluid in the fluid ring 442 to return to the startingtank 401. Next, the poppet valve 443 through which the waste fluidentered the separator 440 is closed and a drying air poppet valve 444 isopened to let drying air into the interior chamber of the separator fluxcartridge 441. This drying air provides a mechanism to dewater theconcentrated waste and drives additional flush fluid through the fluxcartridge 441 membrane and through the return poppet valve 447.Consequently, in one embodiment, the contaminant removed from theconcentrator is substantially dry. In one embodiment, the substantiallydry contaminant is removed from the concentrator by a purge air source.

The drying air poppet valve 444 and fluid return poppet valve 447 arethen closed and a purge air poppet valve 445 is opened to allow inpressurized purging air into the separator 440. When the air pressureinside the separator 440 reaches a pre-determined or desired level (e.g.110 psi), the poppet valve 446 is opened which allows the waste residueinside the flux cartridge 441 to escape into a waste collection tank403. In one embodiment, a plurality of poppet valves are cycledincrementally to control the flow of fluid through the separator. Inalternative embodiments, a settling tank may be used in place of theseparator 440 to permit untreated fluid to be recycled back into thetank 401 or to produce a final product.

Referring now to FIG. 5A, a portion 503 of a single flux cartridge 120as shown in FIGS. 2-4 illustrates filtration in more detail according toone embodiment of the present invention. The flux cartridge 120comprises the membrane that filters the contaminants from the untreatedfluid 501, 160. In one embodiment, the porous matrix of the filtermembrane 503 is created by pressing or sintering metal powder, metalfibers, woven metal mesh, or any combination of these materials, at highpressure and then annealing it using well-known metallurgical techniquesknown in the metallurgical art. In alternative embodiments, the filtermembrane 503 may consist of ceramic materials, high strength plasticsand other known material as known in the art.

This type of filter membrane provides filtration at both its surface andin its depth. Specifically, although the pores at the surface of thefilter membrane 503 may be larger than the filter specification, theflow path through the filter is tortuous and contaminant particles areintercepted by the metal media. Sintered metal media typically exhibit ahigh porosity and, therefore, high flow rate and low pressure drop withexcellent contaminant particle retention. In one embodiment, the presentinvention uses a lower membrane thickness than those typically found inthe prior art (e.g. 0.125 inches (3.2 mm) instead of a prior artmembrane thickness of about 0.40 inches (10 mm)). A thinner filtermembrane 503 produces a much higher flow rate of fluid through thefilter membrane. Lower thicknesses may also be utilized, in part,because of the controlled fluid turbulence which is present in the fluidring 160 during operation of the invention disclosed herein. In thedisclosed embodiment, the preferred fluid ring length (l) is 0.125inches (3.2 mm) when used in conjunction with a flux cartridge diameterof 0.375 inches (9.5 mm). These dimensions have been found to optimizethe volume of reverse flush fluid required to clean the separator annuliand to minimize the amount of reverse flush fluid required to clean theseparator annuli. To obtain effective filtration and reverse flushefficiencies utilizing the apparatus embodiment described herein, thedesired ratio of fluid ring length (l) to the diameter of flux cartridgeutilized is typically 1 to 3, when using a 0.375 inch (9.5 mm) diameterflux cartridge.

The turbulent flow of the untreated fluid in the fluid ring 160 isrepresented by a curved arrow 510. This turbulent flow is created andcontrolled by the pressure differential and the rhythmic pumping actionof the pneumatic pump (pump 410 in FIG. 2A) and actuation of the poppetvalves within the valve head assemblies of the separator. As the outletstream poppet valves (i.e. 423, 424 in FIG. 2A) of the first pneumaticpump open and close with the pumping action, a temporary drop inpressure in the fluid ring 160 is caused when the poppet valves switchposition (open or closed), creating a sudden velocity differential andcorresponding pressure drop in the fluid ring. This effect is magnifiedby the suction and pulsing action after each infusion of fluid as thepoppet valves open and close. As a result, fluid pulses up and downwithin the fluid ring 160 resulting in the turbulence represented by thearrows 510 in FIG. 5A. This turbulence is again magnified by the highvelocity of the fluid moving through the relatively small volumetricspace in the fluid ring.

Laminar flow consists of fluid flowing in straight lines at a constantvelocity. If the fluid hits a smooth surface, a circle of laminar flowresults until the flow slows and becomes turbulent. At fastervelocities, the inertia of the fluid overcomes fluid frictional forcesand turbulent flow results producing eddies and whorls (vortices). Thepresent invention uses turbulent fluid flow for improved molecular andparticle kinetics such that only the desired, smaller molecules 530(e.g. fluid) pass through the membrane matrix 503. In one embodiment, topass through the fissures of the flux cartridge membrane 503, a moleculein the fluid ring 160 has to enter interstices or fissures at almost a90 degree angle or perpendicularly to the surface of the membrane 503when the molecule enters the membrane (as represented by the arrow at aright angle 520). Due to the constant fluid turbulence, only the lightermolecules are able to make this turn quickly enough to pass through themembrane 503 and enter the interior chamber of the flux cartridge. Heavymolecular contaminants (e.g. suspended solids, iron complexes, oil andgrease) cannot turn fast enough to reach the appropriate entry vector orangle when they contact the membrane 503. As shown in FIG. 5A, whenheavier molecules hit the uneven surface of the membrane surface, ratherthan pass through, they careen off and strike similarly sized molecules,causing them in turn to scatter and thereby increase the kinetic energypresent in the fluid ring between the annulus and flux cartridge. Thiskinetic pattern is illustrated by arrow 540. In the absence of fluidturbulence or when laminar fluid flow conditions exist, the heaviermolecules in the fluid would lose a majority of their kinetic energy andwould not be able to enter the membrane. Thus, fluid turbulence isnecessary to keep the heavier molecules bouncing off the surface ofmembrane 503. As fluid turbulence increases, the smaller a molecule hasto be in order to be properly oriented to pass through the membrane 503.Therefore, the filtration of smaller molecules can be accomplished byusing a flux cartridge with a less porous membrane matrix by increasingthe fluid turbulence within the separator fluid ring 160 or by acombination of the two.

The present invention also provides a novel method of achieving thefiltration by membrane emulation since the filtering effects of asmaller membrane matrix can be achieved without actually changing theporosity of the flux cartridge interstices. Referring back to FIG. 2A, aslipstream poppet valve 425 controls the flow of fluid from theseparator fluid ring 160 to a slipstream fluid hose or path 404 thatfeeds back to the start tank 401. During membrane emulation, thisslipstream poppet valve 425 is opened while the first pneumatic pump 410is pumping pressurized untreated fluid into the separator fluid ring160, which allows the untreated fluid to move through the fluid ring 160at a faster velocity due to the increased pressure differential. Whenthe poppet valve 425 is opened, flow in the fluid ring 160 issubstantially vertical in the depicted orientation of the separator. Dueto frictional forces imparted by the inner and outer circumference ofthe fluid ring 160 on the influent fluid, the velocity profile isparabolic meaning that the influent fluid velocity increases as thedistance away from the either the inner or outer circumferenceincreases. Consequently, particles will agglomerate on the surface ofthe flux cartridge 120 as “cake” thereby continually decreasing theeffective pore size of the flux cartridge. In effect, this reduces thesize of particles which are able to pass through the reduced “cake” porespace of the flux cartridge 120. As a result, the ability to create thiscondition on the flux cartridge allows the operator to “emulate” afilter porosity which is smaller than the physically measured porosityof the flux cartridge 120. With this membrane emulation technique, thepresent invention is able to turn, for example, a five micron fluxcartridge into the functional equivalent of a one micron flux cartridgeby manipulating the pressure and flow conditions existing in theseparator fluid ring 160 due to the large pressure differential createdby the slipstream path 404.

The present invention also provides a way to remove dissolved materialssuch as brine from untreated fluid utilizing hydrodynamic cavitation.Cavitation is defined as the formation, expansion, and implosion ofmicroscopic gas bubbles in liquid. Cavitation occurs in a fluid when thestatic pressure of a fluid falls below its temperature-related vaporpressure. A forceful condensation or implosion of the bubbles occurswhen the fluid reaches a region of higher pressure.

There are generally three regions where chemical and physical phenomenaoccur in cavitation: (1) the gas phase within the cavitation bubblewhere elevated temperature and high pressure are untreated, (2) theinterfacial zone between the bubble and the untreated fluid or solutionwhere the temperature is lower than inside the bubble but still highenough for certain reactions to occur, and (3) the untreated fluid atambient temperature wherein reactions and diffusion are taking place.Without being bound by theory, it is believed that the turbulent forcesexisting during the filtration cycle of the present invention createpulsating energy waves that cause hydrodynamic cavitation to occur inthe separator which results in both physical and chemical changes tocontaminants in the influent fluid, such as dissolved matter,hydrocarbons and more complex chemical structures. During the cavitationphase, very localized, extremely high temperatures (perhaps greater than5000 K) (“hot spots”) and pressures (perhaps greater than 1000 atm) arecreated within the fluid bubbles during the collapse of microscopicvacuoles. Due to the presence of these pressure and temperatureextremes, the influent fluid is subjected to various physical andchemical phenomena including, but not limited to, ionic/covalent bonddestruction, flocculation, precipitation, the creation of free radicals,oxidation reactions and other chemical physical phenomena. Under theseextreme conditions, it is believed that organic compounds aredecomposed. Other compounds or species present in the surrounding fluidalso undergo reactions comparable to those found in standard hightemperature combustion reactions. Cavitation reactions may result in thecreation of free radicals which in turn promote oxidation reactions thatdecompose organic species in the untreated fluid. For example,cavitation of fluid can cause dissociation of fluid into hydrogen andhydroxide. The free hydroxyl radical OH is a powerful oxidizing agentand can facilitate removal of dissolved organic material from thetreated fluid. Oxidation caused by hydrodynamically inducing cavitationis known to be orders of magnitude stronger than oxidation caused by theultrasonic induction of acoustic cavitation.

It is also believed under such a hot-spot model that the maximumtemperature realized in a collapsing bubble decreases as the thermalconductivity of the dissolved or entrapped gases increase. Becausehigher hot spot temperatures are believed to be more advantageous forthe degradation of some contaminants, in one embodiment the thermalconductivity of the dissolved gases in the fluid ring 160 is physicallyor chemically lowered. For example, to physically lower the thermalconductivity, in one embodiment air or other gas is cooled prior tobeing supplied to the fluid ring 160. In one embodiment, the separator100 unit is cooled by any suitable method known in the art.

FIGS. 5B-5C provide a more detailed view of the tortuous path theinfluent fluid travels as it is forced through the separation media, inaccordance with one embodiment of the present invention. As discussedabove, cavitation is defined as the formation, expansion, and implosionof microscopic gas bubbles 554 in liquid. The shockwaves created by thecavitation may accelerate particles 556 to high velocities and increaseinter-particle collisions and particle kinetics. Additionally, localizedspots of high temperature and high pressure gradients temporarily existduring the final phase of bubble implosion. The presence of theselocalized high temperature and high pressure gradients, in addition tothe kinetic energy formed by the shockwaves, may encourage thedecomposition of larger molecules by both mechanical and thermal means.For example, the mechanical energy imparted on large molecules, such asoil, grease or polymers in the filter media may be analogous to pushing,extruding, or forcing a large circular molecule through a smaller “pipeor pore” and may force the intra-molecular bonds to be overcome.Cavitation may also occur or be present in the inner fissures orinterstices of the flux cartridge membrane and/or the interior of theflux cartridge in the vicinity of the flux cartridge membrane during thefiltration cycle or in the vicinity of the fluid ring during theejection cycle.

Referring back to FIG. 5A, as the treated fluid passes through theinterstices of membrane 503 cavitation results and gas bubbles areuntreated. When these gas bubbles reach the inner fissures of the fluxcartridge and membrane 503 (e.g. arrow 530) they begin to rapidlyimplode. During this implosion process, similar and dissimilar moleculesflocculate and form precipitates. Molecular bonds are broken and freeradicals are created further enhancing the filtration process. Anothereffect on untreated fluid by the separation media is the breakup ofemulsions in the treated fluid. As the influent fluid is pushed throughthe separation media or flux cartridge membrane 503 under pressure and,as cavitation reactions occur, emulsions in the fluid are broken. Byusing different size filter matrices and fluid velocities, the presentinvention is capable of separating particles 300 microns in size andsmaller. The different flux cartridge porosities which may be utilizedprovide a variety of conditions that can be manipulated to cause desiredamounts and rates of cavitation.

With reference to FIG. 5A, large particles in the untreated fluid canbuild up along the outer perimeter of the flux cartridge 120 in thefluid ring 160. Such build-up is especially likely to occur at the firstfilter pod or when there is a step change to a filter pod having a fluxcartridge membrane with a smaller micron filter matrix. As a result, thefirst filter pod to process untreated fluid or the first filter podwhere there is a step change in the micron size of the filter matrix mayfunction more as a traditional pressure filter by mostly removingsuspended solids than as a cavitation device. Such build-up material canbe backflushed by a pressure exerted on fluid, for example, by a firstpneumatic ejector 430 (shown in FIG. 2A) through the flux cartridge 120and into the fluid ring 160.

The separation apparatus and method disclosed herein can be enhancedwith the addition of various other separation methods to the separatoras discussed in detail below.

Biocide

In one embodiment, the filter membrane 503 comprises a ceramic fluxcartridge. Ceramic flux cartridges are known in the art and areavailable from vendors such as Doulton USA of Southfield, Mich., USA. Inone embodiment, filter membrane 503 acts as a biocide to destroybiological material in the untreated fluid. In one embodiment, the fluxcartridge is impregnated with a biocide. In one embodiment, the filtermembrane 503 further comprises a colloidal silver-impregnated ceramicfilter. Such impregnated filters are known in the art as illustrated byU.S. Published Patent Application No. 2007/0110824, which is herebyincorporated by reference. Other methods of manufacturing filtermembranes 503 incorporating a biocide will be apparent to those of skillin the art.

Electrochemical Cell

FIG. 5D is a schematic diagram illustrating a cross section of a singleflux cartridge unit comprising an electrochemical cell according to oneembodiment of the present invention. In one embodiment, the fluxcartridge 100 comprises two or more electrodes and an electrical currentsource. As shown in FIG. 5D, in one embodiment, the flux cartridge 100comprises two cathodes 170, one anode 180 between the two cathodes, andan electrical current source 190. Such cells are known in the art asexemplified by WO 99/16715 and U.S. Pat. No. 4,384,943, both of whichare hereby incorporated by reference in their entirety. In oneembodiment, the electrodes 170,180 are circumferential plates and can beperforated to facilitate the flow of fluid within the fluid ring 160. Asshown in FIG. 5D, a cathode 170 is on each longitudinal side of theanode 180. However, such embodiment is provided for purposes ofillustration and not limitation and any suitable arrangement can beused. In an embodiment not shown, the casing 110 itself can be anelectrode. In one embodiment, the anode 180 can be made of titaniumcoated with a catalytic coating or can be made of another suitablemetal. In one embodiment, the cathode 170 can be made of steel. In oneembodiment, the electrochemical cell is used to precipitate out metalsand dissolved constituents in the fluid in the fluid ring during theseparation cycle which is then removed via the backwash ejection cycledescribed herein. Likewise, if sufficient current is used, theelectrochemical cell is used to destroy biological material within thefluid ring 160.

Electromagnetic Field

FIG. 5E provides a more detailed cross-sectional view of the fluxcartridge subjected to a magnetic field in accordance with oneembodiment of the present invention. In one embodiment, the untreatedfluid is subjected to a magnetic force, magnetic field or magneticgradient upon entry into the fluid ring of a separator to collect oragglomerate solid particles affected by such magnetic field. Suchfiltration methods are known in the art as disclosed in U.S. PatentPublication No. 2006/0191834, which is hereby incorporated by referencein its entirety. The magnetic force can significantly affect particlemovement during the filtration process, in some cases contributing tothe formation of a filter cake on the surface of the flux cartridge (notshown) and/or on the inner surface of the outer casing 110 as depictedin FIG. 5E. When the particles agglomerate into larger molecules 210,there is an increase in their effective diameter in turn increasing thefiltration efficiency of the flux cartridge unit. The magnetic field canbe applied at any angle to the direction of pressure driving theuntreated fluid through the flux cartridge, whatever proves mosteffective for the fluid undergoing filtration. The field can be appliedparallel, perpendicular, or at any angle in relation to the direction offluid flow. The means for subjecting a magnetic field or gradient to theuntreated fluid may include a solenoid attached to or contained withinthe filter pod or flux cartridge or a permanent magnet internal orexternal to the filter pod and/or flux cartridge. Typical ranges ofhomogenous magnetic field strengths which would be useful in thisapplication are greater than 0.01 T.

In one embodiment, the flux cartridge 100 is subjected to a magneticfield such that when fluids having magnetic materials such as ironfilings, enter the annulus, the magnetic field can be activated so thatthe magnetic materials are moved outwardly in the direction shown by thearrows. Consequently, the magnetic materials are attracted toward andretained on the outer casing 110 in the fluid ring 160. Then, just priorto or immediately after the backwash operation is initiated, the fieldcan be released and the retained magnetic materials are flushed out ofthe annulus during the backwash ejection cycle.

Acoustic Cavitation via Ultrasound

In one embodiment, the hydrodynamic cavitation caused by themanipulation of pressures within the separator and filter medium iscoupled with acoustic cavitation to further enhance the overallcavitation reaction that occurs in the molecular separator. In oneembodiment, an ultrasonic wave source is coupled to the flux cartridge100 to create acoustic cavitation. As used herein, “acoustic cavitation”is defined as ultrasonically-induced cavitation. Stated differently,“acoustic cavitation” is the formation, growth, and collapse of bubblesoccurring as from an ultrasound source. Ultrasonically-inducedcavitation can be provided by an ultrasound probe inserted into thefluid ring of the flux cartridge 120. In one embodiment, the filtermembrane 503 comprises one or more ultrasonic probes to facilitateacoustic cavitation.

There are two types of acoustic cavitation stable and transient.Transient cavitation occurs at greater acoustic pressures, where bubblesviolently implode after a few cycles. This implosion can have a numberof effects, including transiently raising the local temperature byhundreds of degrees Celsius and the local pressure by hundreds ofatmospheres, emitting light by the phenomenon called sonoluminescence,creating short-lived free radicals, which in turn promote oxidationreactions that decompose organic species in the untreated fluid.Acoustic cavitation can affect a number of acoustic chemical andbiological changes in a liquid. Consequently, in one embodiment,transient acoustic cavitation is used to destroy the biological materialin untreated fluid. Transient acoustic cavitation can occur atfrequencies between about 20 and about 350 kHz. Stable acousticcavitation can occur at low-pressure portions of an ultrasound wave andcan occur at frequencies between about 700 and 1000 kHz. Because stableacoustic cavitation bubbles have less time to grow, they are smaller andtherefore result in a less vigorous implosions and collapse than occursin transient acoustic cavitation.

Example of Untreated Fluid Treatment Array

FIG. 6A is a schematic diagram of one embodiment of the presentinvention depicting multiple treatment stages in series. With referenceto FIG. 6A, untreated fluid is passed in series through multipleseparator filter pods or stages. Impurities are concentrated andcollected from one or more stages into a separate receptacle. Treatedfluid is collected at the end of the stages in series. Stages can beadded as desired to further filter impurities from untreated fluid. Eachstage may contain a flux cartridge having the same porosity (e.g. fivemicrons). Alternatively, successive stages may have successively smalleror successively larger porosities. Further, successive stages may havean apparent random variation of porosities which are selected byexperimentation so as to effect a desired separation or filtrationdepending on the chemical and physical makeup of the untreated fluid.For example, a first stage may use lone hundred micron flux cartridgeswhile a second stage may use five micron flux cartridges. Any number ofsuccessive stages in series may be used until desired fluid purity isobtained. A reverse osmosis system can then be used to remove anyremaining dissolved solids in the fluid.

FIG. 6B is a schematic diagram of another embodiment of the presentinvention depicting multiple stages in series and in parallel. Withreference to FIG. 6B, the capacity to filter contaminated fluid can beincreased by adding stages in parallel. Also, the degree of filtrationand resultant treated fluid can be similarly controlled by adding stagesas desired in series. A reverse osmosis system can then be used toremove any remaining dissolved solids in the fluid. In one embodiment,the treated fluid in FIG. 6A or the filtered fluid in FIG. 6B can befurther treated with a hydrocarbon removal media such as activatedcarbon and/or other suitable material such as is available from MycelxTechnologies Corporation of Gainesville, Ga., USA.

FIG. 6C is a schematic diagram of one embodiment of the presentinvention depicting multiple first stages in parallel and the remainingstages in series. With reference to FIG. 6C, untreated fluid is fed intomultiple filter pods at stage one before being combined and sent througha single pod for each of the remaining stages. The treated product iscollected at the end of the process. The concentrated impurities aretaken from stage one and from each of the stages. Any number of pods orstages, such as the arrangement shown in FIG. 6C, may be assembled intoa unified functioning apparatus.

The embodiment shown in FIG. 6C is especially advantageous if there arelarge amounts of relatively large suspended solid impurities in theuntreated fluid which clog the pores of the first set of fluxcartridges. The impurities are drawn off at the first stage by ejectioncycles. Further, it may be desirable to operate the filtration andejection cycles at a much greater frequency in the earlier stages tofurther ensure that particles and impurities do not excessively becomebound in the pores of the flux cartridges. The filtration and ejectioncycles at each stage may be performed at any rate at any given stagewhether the stages are in parallel or in series.

FIG. 6D is a schematic diagram depicting a series of filter stageshaving decreasing filter membrane sizes and a heat source. Withreference to FIG. 6D, filtration of untreated fluid is improved by theuse of heat to lower the viscosity of the aqueous solution. The lowerviscosity improves the flow of fluid through the filter membranes andespecially through the smaller porosity filter membranes. Lowering theviscosity also lowers the resistivity of the fluid and permits suspendedcontaminants to settle out of solution where they can be more easilybackflushed during an ejection cycle into a settling tank (not shown).

It should be further noted that the various streams and/or fluxcartridge can also be cooled to cause contaminants such polymers orflocking agents (common constituents in drilling fluids) in theuntreated fluid to become brittle and/or precipitate out of solution inthe fluid ring. Consequently, in one embodiment, one or more of the fluxcartridges comprising the first stage are cooled to precipitate outcontaminants in the fluid ring. In one embodiment, the untreated fluidis cooled prior to entering the fluid ring to precipitate out componentsprior to entering the first separator.

Ultraviolet Disinfection

It should be further noted that other treatment technologies besidesheat can also be applied in unit operations placed in before, between orafter molecular separators as depicted by the heat source in FIG. 6D.For example, in one embodiment, ultraviolet radiation (UV) is used tobreak down organic contaminants and inhibit bacterial growth. UVdisinfection transfers electromagnetic energy from a mercury arc lamp toan organism's genetic material (DNA and RNA). When UV radiationpenetrates the cell wall of an organism, it destroys the cell's abilityto reproduce. UV radiation, generated by an electrical discharge throughmercury vapor, penetrates the genetic material of microorganisms andretards their ability to reproduce. The effectiveness of a UVdisinfection system depends on the characteristics of the waste fluid,the amount of time the organisms are exposed to the UV radiation, andthe reactor configuration.

The optimum wavelength to inactivate organisms is in the range of 250 to270 nm. Low pressure lamps emit essentially monochromatic light at thewavelength of 253.7 nm. Standard lengths of low pressure lamps are 0.75m to 1.5 m with diameters of 1.5 cm to 2.0 cm. Generally, two types ofUV reactor configurations exist: contact types and noncontact types. Inboth configurations, the fluid to be treated can flow parallel orperpendicular to the lamps. In the contact reactor, a series of mercurylamps are enclosed in quartz sleeves over which the fluid to bedisinfected is routed. As the fluid passes over the lamps, UV radiationpenetrates the cells of organisms suspended in the fluid and effectively“kills” the organism. In a noncontact reactor configuration, UV lampsare suspended outside a transparent fluid conduit, which carries thefluid to be disinfected. In both types of reactors, a ballast or controlbox provides a starting voltage for the lamps and maintains a continuouscurrent.

The advantages of UV disinfection include: (1) effective inactivation ofmost spores, viruses, and cysts, (2) UV disinfection leaves no residualeffect that can be harmful to humans or aquatic life, and (3) UVdisinfection has a shorter contact time when compared with other formsof disinfection (approximately 20 to 30 seconds with low-pressurelamps).

FIG. 7 is a schematic diagram of a series of four filter separatorannuli 701, 702, 703, 704 each having a flux cartridge 710 in accordancewith one embodiment of the present invention and illustrating theprinciple shown in FIG. 7. As in FIG. 2A, the annuli in FIG. 5 are forillustrative convenience and represent one or more annuli in a filterpod. Similarly, although a single series of separator annuli isillustrated in FIG. 7, several such parallel operations may worktogether to increase production volume as shown by the portion of FIG. 7titled “optional parallel operation.”

With reference to FIG. 7, untreated or production fluid 760 is routed bya pump (P) 750 to a first filter annulus 701 with a flux cartridge 710having an effective porosity of 100 microns. A fluid ring 720 existsbetween the inside surface of each annuli 701, 702, 703, 704 and theouter surface of its corresponding flux cartridge 710. The effluent 711Afrom the first flux cartridge 710 passes into a second filter annulus702 wherein it is further treated with a second flux cartridge 710having an effective porosity of 40 microns. A second pump 750 passes thetreated effluent from the second annulus 702 into the third annulus 703wherein the fluid is treated a third time through a flux cartridge 710having an effective porosity of 10 microns. Finally, the treatedeffluent from the third annulus 703 is passed into the fourth annulus704 wherein its flux cartridge has an effective porosity of one micron.The treated fluid is then transported to a storage tank or can be routedto a settling tank for blending operations.

In the embodiment shown, the pumps (P) 750 and ejectors (E) 751, 752pneumatically operate at different time intervals that can cycle betweena filtration cycle (when the pumps P are operating) and an ejectioncycle (when the ejectors E are operating) or the ejectors can operate onindividual annuli/separators as desired. For example, the filtrationcycle can occur for a pre-determined amount of time and at the end ofthis pre-determined amount of time each separator unit or Q-pod can bebackwashed with a reverse flush from the ejector E as explained inregard to FIG. 2A. In alternative embodiments, variables with or withouttime can be used to determine the length of each cycle interval. Onesuch variable may be an average pressure differential that developsacross the flux cartridges 710 of each Q-pod. In one embodiment, thefiltration cycle causes an average pressure differential across the fluxcartridge membrane of between about 30 and 50 psi (0.2 and 0.35 MPa) andthe ejection cycle causes an average pressure differential across theflux cartridge of between about 100 and 300 psi (0.7 and 2.0 MPa).Vigorous backwash forces refresh each flux cartridge and help maintainthe turbulent fluid dynamics occurring within the fluid ring of eachfilter unit. The filtration cycles and ejection cycles can be optimizedbased upon the amounts and types of contaminants in the untreated fluid.

In a further embodiment, the filter membrane or flux cartridge cancomprise a catalyst (e.g. cobalt-molybdenum, alumina, aluminosilicatezeolite, palladium, platinum, nickel, and rhodium) to enhance chemicalreactions within the separator to further the removal of contaminates.Such catalyst should be selected so as to target a particular chemicalcompound or element, or set of chemical species present in the influentfluid.

In another embodiment, a heated or non-heated gaseous stream can be usedto aerate the untreated fluid or any of the streams in the process. Suchaeration may occur before any filtration, at any stage of filtration, orbetween stages of filtration. Such additional gaseous stream furtheraids in filtration and separation of contaminants from the fluid. Oxygenor other gaseous species chemically reacts with the contaminants furtherimproving the quality of the treated aqueous product. For example, aheated air, oxygen stream, or hydrogen stream can be added at any stageto the aqueous stream being treated. The examples of heated andnon-heated gases are provided for purposes of illustration and notlimitation.

In one embodiment, the present invention includes a control panel whichincludes a plurality of control inputs for monitoring and operating themolecular separator apparatus by a user. For example, control inputs canbe connected to one or more pieces of equipment, such as pumps, toactivate and deactivate the pumps and/or to monitor pressure at variousplaces on the pump. Control inputs can also be used to monitor and/orcontrol the use of the poppet valves pneumatically and/or electrically.

The instant invention results in numerous advantages. First, it providesan efficient method for cleaning or filtering untreated fluid to thepoint where it may be potable or may be further treated to becomepotable. Such invention reduces the cost of treating contaminated fluidand/or generating cleaner, usable fluid. Second, the invention providesa way to clean untreated fluid such that the effluent complies withenvironmental standards. Such cleansed fluid may be safely released tothe surface or re-injected back into the ground, and the contaminantsmay be further concentrated and can then be more appropriately disposedof or used. Third, the invention can help to provide a more stable feedstock to other processes requiring a cleaner low-cost aqueous stream.Fourth, the invention is easily transported by skid and can be placed inalmost any location worldwide. Pumping and transportation costs arethereby reduced as contaminants are removed closer to the source ofcontamination. In one aspect, the separator apparatus is detachablysecured to a wheeled transport for placement at or near the source offluid to be treated. Fifth, it provides for a more economical overallfiltration operation.

Having thus described several aspects of at least one embodiment of thisinvention, it is to be appreciated that various alterations,modifications, and improvements will readily occur to those skilled inthe art. Such alterations, modifications, and improvements are intendedto be part of this disclosure, and are intended to be within the spiritand scope of the invention. Accordingly, the foregoing description anddrawings are by way of example only. While the invention has beenparticularly shown and described with reference to a preferredembodiment, it will be understood by those skilled in the art thatvarious changes in form and detail may be made therein without departingfrom the spirit and scope of the invention.

1. A separator apparatus for treating a contaminated fluid, comprising:at least one separator with at least one annulus disposed therein; aflux cartridge with a semi-permeable membrane seated inside saidannulus, wherein a fluid ring exists between an interior surface of theannulus and an exterior surface of the flux cartridge; a first pump influid communication with the separator capable of delivering an influentfluid containing at least one contaminant into the separator, whereinthe pressure delivered by the first pump results in cavitation withinthe fluid ring of the separator resulting in the retention ofcontaminant particles on the exterior surface of the flux cartridge andthe collection of the filtered fluid within an interior chamber of theflux cartridge; a second pump in fluid communication with the separatorcapable of reversing the flow of fluid through the flux cartridge,wherein filtered fluid is pumped into the fluid ring from the interiorchamber of the flux cartridge which provides for the removal of thecontaminant particles retained by the flux cartridge and transports asubstantial portion of the contaminant particles out of the separator; areject tank in fluid communication with the separator which receives asubstantial portion of the contaminant particles from the separator; anda product tank which receives a substantial portion of the filteredfluid from the separator.
 2. The apparatus according to claim 1, furthercomprising: at least one concentrator in fluid communication with theseparator, containing at least one concentrator annulus disposedtherein; and, a concentrator flux cartridge with a semi-permeablemembrane seated inside the concentrator annulus, wherein a fluid ringexists between the interior surface of the annulus and the exteriorsurface of the flux cartridge, wherein a substantial portion of thecontaminant waste and fluid flushed from the separator enters theinterior chamber of the flux cartridge seated within the concentratorand wherein the contaminant of a desired dimension is retained on theinterior surface of the concentrator flux cartridge and a substantialportion of the filtered fluid is collected in the fluid ring of theconcentrator.
 3. The apparatus according to claim 1, further comprising:a plurality of separators which are operated in at least one of a seriesor parallel configuration.
 4. The apparatus according to claim 1,further comprising: a reverse osmosis membrane in fluid communicationwith the separator.
 5. The apparatus according to claim 1 wherein atleast one flux cartridge is impregnated with a biocide.
 6. The apparatusaccording to claim 1 wherein at least one separator comprises anelectrochemical cell.
 7. The apparatus according to claim 1 wherein atleast one separator is subjected to a magnetic force.
 8. The apparatusaccording to claim 1 wherein at least one separator is coupled with anultrasonic wave source.
 9. The apparatus of claim 1 further comprising:at least one transition plate in fluid communication with the separatorfor distributing the influent fluid stream into the separator.
 10. Theapparatus according to claim 1, further comprising: a slipstream fluidpath in fluid communication with the separator which acts to enhance theturbulent flow of contaminated influent within the separator therebyimproving the filtration efficiency of the separator.
 11. The apparatusaccording to claim 1, further comprising: a control panel which includesa plurality of control inputs for monitoring and operating the separatorapparatus by a user.
 12. The apparatus according to claim 1 wherein thefirst pump pumps contaminated fluid influent into the separator throughtwo alternating fluid paths, wherein the fluid influent is moved throughthe first path by the upward movement of a piston inside the first pumpand is moved through the second fluid path by the downward movement ofsaid piston.
 13. The apparatus according to claim 1, further comprising:a hydrocarbon removal unit in fluid communication with the separator.14. The apparatus according to claim 1, further comprising: a heatsource in fluid communication with the separator.
 15. The apparatusaccording to claim 1, further comprising: an ultraviolet disinfectionsource in fluid communication with the separator.
 16. The apparatusaccording to claim 1 wherein only one separator is in fluidcommunication with the second pump and wherein the flow of fluidreceived from the second pump is alternated between a plurality ofseparators at regular intervals and the treated fluid from the pluralityof separators that are not in fluid communication with the second pumpbypass the second pump and flow directly into a collection reservoir.17. The apparatus according to claim 1 wherein at least one poppet valvecontrols the flow of fluid into the separator.
 18. The apparatusaccording to claim 1 wherein a plurality of poppet valves are cycledincrementally to control the flow of fluid through the separator. 19.The apparatus of claim 1 wherein the separator apparatus is detachablysecured to a wheeled transport.
 20. The apparatus of claim 1 whereinsaid flux cartridge comprises a reusable filter. 21-33. (canceled)